1.

INTRODUCTION TO ABG SHIPYARD

1.1 ABOUT THE TRAINING ORGANIZATION: ABG Shipyard Ltd., the flagship company of ABG group was incorporated in the year 1985 as Magdalla Shipyard Pvt. Ltd. with the main objects of carrying Shipbuilding and Ship Repair business. In a span of 20 years from the year 1991, the company has achieved the status of the largest private sector shipbuilding yard in India with satisfied customer base all around the world. The registered office and the yard are situated at Surat in the state of Gujarat and the corporate office is in Mumbai. The Shipyard has state of the art, manufacturing facilities including a Ship-lift Facility with a lift capacity of 4500 tons, side transfer facilities, CNC plasma cutting machine, Bending rolls, Hydraulic press, Cold shearing machine, Frame bending machine and steel processing machinery. The Shipyard also has blasting shop and fabrication shop covered in 4 bays of 150 x 30 M each equipped with 20T EOT Cranes. The manufacturing process is in line with world-class standards and the Yard is certified by DNV for ISO 9001:2008. During past decade, the Shipyard has constructed and delivered One Hundred forty four(144) Vessels including Specialized and Sophisticated vessels like Interceptor Boats, Self Loading and Discharging Bulk Cement Carriers, Floating Cranes, Art couple Tugs and Flotilla, Split Barges, Bulk Carriers, Newsprint Carriers, Offshore Supply Vessels, Dynamic Positioning Ships, Anchor Handling Tug Supply Vessels, Multi-purpose Support Vessel, Diving Support Vessels, etc. for leading companies in India and abroad. The Yard has Multiple Building Berths, 2 Dry-docks, 125 m x 22.5 m x 5.6 m Fitted with Computerized Synchronous Shiplift Platform, of 4500 tonnes Lifting Capacity and 155 m X 30 m x 7.5 m, Graving Dry dock served by 80-T Goliath Crane span 50 m, height 35 m. and substantial cranage like NCK Rapier 150T Capacity, Tata P & H Make, 60-T Capacity, HM Make, 50-T Capacity, PPM 80T Capacity3 Tower Cranes, 11 Gantry Cranes of suitable capacities. The Ship lift Facility enables the yard to simultaneously build and repair many vessels and gives the yard a tremendous logistical advantage and flexibility
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1.2 PRODUCT RANGE: 1. 155m 20K DWT bulk carrier 2. oceanic graphic research vessel. 3. 94m Pollution control vessel 4. 91m 4 NO. of 130 bollard pull vessel 5. 91m Diving support vessel 6. Towing vessel 7. 130m 10K DWT bulk carrier 8. 74.5m 2950 DWT dumb barge 9. 78m multipurpose vessel 10. 78.7m Platform supply vessel 11. Oil recovery vessel 1.3 INFRASTRUCTURE & SERVICES

Fig 1.1: ABG Shipyard

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Shipyard Area: Approx. 140, 000 m2 (35 Acres). Jetties:

2 Nos. Each 32.36 x 9.0m 1 No. Dolphin jetty of size 19.02 x 9m.

Administrative Building:
Office consists of three floors with modern amenities, independent rooms for Surveyors and Owners. All departments are accommodated in the administrative building.

Stores:

Covered: 700 m2. Open: 4000 m2. Bonded: 2000 m2 (Served by 30 T Goliath Crane).

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1.4 DRY DOCKS & WORKSHOPS

Fig 1.2: Drydock

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Fig 1.3: Dry Dock fitted with Computerized Synchronous Ship lift

1.4.1 Dry Docks:

Dry Dock 1: 125 m x 22.5 m X 5.6 m. Fitted with Computerized Synchronous Ship lift Platform, of 4500 Tones Lifting Capacity. Graving Dry Dock 2:155 m x 30 m x 7.5 m. served by 80 T Goliath Crane span 50 m, height 35 m.

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1.4.2 Covered Fabrication Shops:

Fig 1.4 Fabrication Shop

4 Covered Bays are presently available at the Shipyard site: 1st Bay consisting of 150 x 30M, 10 MT EOT & 15MT EOT, CNC Cutting, Cold Frame Bending, Press, Rolling machines. 2nd Bay and 4th Bay consisting of 150 x 30M with 10 - 15MT EOT for block fabrication. 3rd Bay consisting of 150 x 12M, 10 MT EOT for Steel Fabrication / Aluminum Fabrication.

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1.5 MATERIAL HANDLING EQUIPMENTS:

Fig 1.5: Material Handling Equipments

NCK Rapier 150T Capacity Tata P & H Make, 60 T Capacity ABG Cranes Make, 80 MT Capacity KAMAG Make,135 T Capacity transporter HM Make, 50 T Capacity PPM 80 T Capacity Tata P & H Make, 20 T Capacity Goliath Crane Span of suitable capacities
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 Forklift EOT 10 T, 15T, and 20 T Capacities 1.6 Blasting Shop:

Fig.1.6 Sand blasting machine

30 x 24 m covered for Blasting of Fabricated Units. Shop equipped with Mechanical Ventilation / Exhaust Trunking and Fans. 30 x 25 m open for Blasting of Plates and Profiles.

Facilities: Complete Painting and Surface Preservation Services Water jet Blasting and Sandblasting
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1.7 SPECIAL WORKSHOP FACILITIES FOR ALUMINIUM FABRICATION:

50 T Forming Squeezer. 400 T Hydraulic Press. Frame bending machine. Sheet Rolling machine Turner lathe machine Uni Mig. Welding M/C Type 330S Jigsaw Cutting M/C T.C Tipped miller machine Trimming machine Reciprocating Saw, Band Saw and Circular Saw Bench Grinder cum Sawing machine Router

1.8 PLUMBING & MACHINE SHOP: 112 x 15 m, Equipped with Plumbing and Machine Tools. Pipe bending machine Heavy duty horizontal lathe(3000diaX 3000m) Lathe machine (450DiaX12Feet) Lathe machine (200DiaX1.70m) Power Hacksaw Pedestal grinding machine 200 Dia. Vertical Boring machine (4 meter) Radial drilling machine (80 mm)
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1.9 FACILITIES: Blasting and Painting of Blocks, Hull Assemblies, Pipe Fittings Carried out in open environment by Grit blasting, then priming and final painting. Painting equipment is based on airless spray as standard. Storage areas Covered sheds with vertical and horizontal stacking for steel plates, profiles and pipes. Covered bonded stores area for storing the bought out major equipments & any other item considered under customs supervision and marked for exports. Suitable crane capacity. Other facilities: CNC Plasma arc cutting facilities. Acid pickling unit. Submerged Arc Welding facilities. FCAW welding machines facilities.

1.10 PRODUCTION CAPABILITIES: 14 nominated berths available for hull Berth allocation for an average mix of vessels 45 to 120 meters length. 3 construction Bays presently available with 12 Skids in each Bay. Thus 36 skids available for construction of 10 X 10 Meters blocks. 23 vessels under different stages of production in the shipyard at a given time are possible. 2 jetties can accommodate vessels for stage between launching and delivery.

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1.11 SHIP REPAIR: The Ship Repair Division has successfully repaired and refurbished Dredgers, Ethylene Carriers, Bulk Carriers, Offshore Supply Vessels and Coast Guard Vessels. With the entire infrastructure, equipment and technology at disposal, ABG undertake repairs and overhauling of ships as well. It offers comprehensive repair services including ship conversion, refurbishment, modernizations, up gradation, retrofitting and rebuilding. It has already repaired a host of vessels including tankers, bulk carriers, container vessels, coast guard vessels etc.

Fig.1.7 Ship repairing

1.12 Achievements of ABG ABG Shipyard Ltd. has in the last 2 years won the prestigious award from EEPC (Engineering Export Promotion Council) under the category Highest Growth in Export Non SSI. This award known as All India Award for Highest Exporters was won for the following years: EEPC for the year 1999-2000 EEPC for the year 2000-2001 EEPC for the year 2002-2003
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EEPC for the year 2003-2004 EEPC for the year 2005-2006 EEPC for the year 2006-2007 EEPC for the year 2007-2008 Certificate of Recognition Two Star Export House Certification: ISO 9001 / DNV Bureau Veritas / RVA management System C024

1.13 The Future

The ABG Shipyard plans to make following changes in their layout to increase the ship building capacity.
The area available north of Shed Number 1 shall be used as an additional covered fabrication shed. Shed no 3 which is being used for aluminium vessel construction shall be used for housing the CNC, shearing, rolling, bending, pressing machines. This shift shall provide block making facilities on both sides of this shed. Thus improving the material flow. Construction of 1 additional Dolphin Jetty. A new covered shed next to main dry dock area for construction of Aluminum vessels

1.14 Present Expansion - The Future Dahej Project ABG Shipyard Ltd. propose to set-up a new shipyard capable of building / repairing vessels up to 120,000 DWT at Dahej, Gujarat. Pitching and slope protection is proposed to be constructed to protect the waterfront from erosion due to wave action. Dry docks Two large dry docks admeasuring 400M length, 45M breadth and 10M in depth. Accommodate bulk carriers of up to 120,000 DWT.
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 Concrete floor and concrete vertical side walls with dock gates on river front. Tower crane of large capacity running on rails, spanning across the docks. Diaphragm walls taken to a sufficient depth to support side walls. Cranes in the central crane bay to support operations in the dry dock. Outfitting Quay Outfitting quay will be provided on either side of dry docks and in front of crane bay. Total length envisaged is 300m. This will have a width of 15m. It is proposed to use it in multi functional role. It will function as a loading/unloading platform for equipment transported through sea. Ships being built in the dock can be floated and held against the quay when outfitting of equipment/machinery is required to be done in floating condition. Very large ships can be held across dry dock gate also for some time without holding any activities within dock. At this this time the draft required is a literage draft. Quay width is adequate for movement of trucks/mobile cranes etc.

Fabrication, Assembly and Process Sheds Covered fabrication sheds

Block construction of hulls on modular basis Suitable EOT Cranes for all sheds and also equipped with welding machines.

Common facility shed Consists of common facilities like hydraulic press, CNC machines, etc. Customs bonded warehouses and storage facility sheds Wheel house machinery / equipment like main engines, compressors, DG sets, thrusters, propellers and shafts etc.

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FLOW CHART OF SHIP BUILDING

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Construction of vessel Drawing Approval & Receipt Material Estimation/Procurement Material Receipt and Inspection Surface Preparation & Priming Elements Cutting Sub- assembly of Block Assembly of Block Dry Survey of Tanks/Compt . NDT of Hull Erection of Block Keel Sighting
Electrical

Machinery

Outfit

Piping

Tank Testing Pneumatic/Hydro. ) Hose Test of Comp./ Void Area etc. Under Water Fitting Outer Hull Blasting & Painting

Pipeline System Mach/Equ. Installation

Cable Routing
Commissioning

Draft Marking / Load line marking

Testing of Pipe System

Principle Dimension check

Accommodation works

Vessel Shifting & Launching Inclining Experiment Commissioning & Sea Trial Delivery of Vessel
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2.0 DEPARTMENTS
The ABG shipyard Surat has two units named fabrication unit and erection unit. All the departments have given a particular work allotted to them. The erection unit having all the departments includes following departments: 1. Planning Department: This department deals with the planning of the various activities that the yard has to undertake in the new construction of vessel starting from allotting of jobs to respective department and site engineer to production design and actual fabrication process, it ensures that each activity is carried out on time with any delay and prepares a schedule for the completion of each activity ensuring that there is no delay in production due to material unavailability and manpower etc. It also deals with the aspects like cost monitoring and cost reduction which can help in better revenue for the yard. 2. Hull Department: This department deals with the job related to the hull of the vessel. major parts of the hull department is divided mainly as prefabrication, subassembly, block construction and finally block alignment. The major fabrication is carried out in outside PFS-1 which is well equipped with gantry crane and latest technological machine like CNC cutting machines, CNC frame bending, hydraulic plate bending etc. it also has its own blasting and priming area.sub assemblies are also prepared here. Hull fabrication is also done in west side and at bay 1 and 2 where subassemblies are carried out to prepare the blocks. The blocks once prepared and cleared by quality control are then brought by comettos for final alignment.

3. Piping Department : Piping department deals with the various system on board the vessel which involves fabrication of pipe spools to eraction at site. Testing, cleaning, flushing and final commissioning of the system. Spools
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are fabricated at the fabrications shop in the SHBD west side. The pipe shop is well equipped with pipe bending and hydraulic testing machines and also special areas for acid pickling, galvanizing and flushing of the fabricated spools. Each spools fabricated is cleared by QC after which they are subjected to hydro-test or air pressure or radiography etc. 4. Mechanical department : The Mechanical department deals with various jobs related to the installation of steering system which include fitting of stern tube, propeller shaft, propeller, rudder stock, rudder etc. it also deals with the installation of main engine and other engine room machinery of vessel. The work related to this department range from fitting, installation to alignment test, trials and final commissioning. 5. Quality control and testing : All the inspection work such as checking of fit up, dry survey is done in quality control thereby ensuring that necessary quality and

standard is achieved as required by the customer.

6. Design department: Design department is very important for any shipbuilding industry. To design a whole vessel according to the owners requirement is their responsibility. It is very crucial department for industry as the survival of industry depends on it. It deals with the designing of shape of the vessel, designing of piping system in vessel, design the accommodation facilities in vessel, etc. In ABG it is well equipped with all needed facilities. The design departments have unique software FORAN upon which all the ship designing is done. Only the offset table and lines plan receive from a SEATECH MARINE Singapore. Then the Fairing of these Lines Plan and detailed designing of the drawings is done by the Design department using FORAN and AUTO-CAD software, with the help of these software they do the further work as making a hull profile, Calculating Steel weight, Stability calculations general arrangement plan, shell expansion plan, block division plan, block wise detail designing, preparation of part list, nesting.

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7. Electrical department : The Electrical department deals with all the electrical jobs on the vessel like selection of cables, laying of cables, power management, distribution of power to various systems on board. 8. Outfitting department: The outfitting work on the vessel is generally looked after by the Outfitting department. The major work generally starts after launching of vessel and this includes, paneling, installation of windows, hatch comings, railings, staircases, mast, etc. Finally, the Painting department deals with all the painting and cleaning work. Other work carried by painting department is Sand Blasting, Buffing of tanks, etc. There are some other departments also which are related to non technical work known as assisting departments. They are as follows 1. Fire and safety department 2. Yard maintenance 3. Accounts 4. Administration 5. H.R. department 6. House keeping department 7. Material management

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3. HULL DEPARTEMENT
`

3.1 FRAME AND PLATE PREPARATION When the plates entered in the yard it should have to be prepared for to use. In the preparation process first the plates are blasted then on that have to apply the primer paint coat. Then the diagonal of the plates are checked for corners are right angle or not, grade of the plates is also checked by the symbol on the plates is mentioned this also tells the constituents of the plates. Buckling of the plates is removed by putting the plates in a roller machine. Before fitting the frame stiffeners that is also checked for bending, grade of the stiffeners. Further this plate is ready for use. The plate preparation is process of shot blasting the steel plate using shot and grit to remove mill scale and rust existing on plate surface when received from steel mills. Further, after shot blasting the plates are primed to protect them from further rusting. 3.1.1 SHOT BLASTING Shot blasting is the general term used to describe the process of projecting abrasive particle against the surface of work piece to be cleaned.

Procedure
The plates to be blasted clean are loaded on the roller conveyors from where they are transported to blast chamber. As the work piece approaches the blast station the limit switch provided actuates the abrasive control valve, which feeds the abrasive to blast wheels. Abrasives

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Fig.3.1 Blasting chamber

The abrasive used are shot and grit in the ratio of 3:1. Shots are round and give a smooth finish (size S390) Grit are angular and gives a deeply etched surface (size G18) Shot and Grit are steel and chilled cast iron. The type of surface required can be obtained by using set screw provided on abrasive control valve. Blow off system is provided to remove the abrasive accumulated on surface of the plate after blasting is completed. Blasting profile according to the yard standard should be. Maximum: 40 microns Minimum: 70 microns A separate system is installed to reuse the blasted abrasive.

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3.1.2 PRIMING
After shot blasting the plates are primed in painting booth. Priming is a process of applying preparatory coating on plates. Priming ensures better adhesion of paint to the surface, increases paint durability and provides additional protection to plates before painting.

Procedure
The plates are primed in the painting booth by two automatic sprayers which move along the width of plate. Basic requirements Paint used: Jotun paint Temperature: 28. C to 35. C Paint proportion: Primer: 18 litres Hardener: 0.5 litres Thinner: 1.5 litres Paint pressure: 30bars to 40 bars Paint DFT: 25 to 30 microns Air pressure: 40bars to 45bars Conveyor speed: 1.5 to 1.8 m/m Relative humidity: 45% to 80% 3.1.3 DRYING OF PLATES The plate after priming enters the drying or flash off chamber travelling on slat conveyors. The slat conveyors are provided in drying chamber to protect the coating from getting damaged as slat conveyors come in least contact with plate surface It is used for drying or to exhaust the paint fumes on the plates. Four blowers are employed for plate drying. After the plate arrives out of drying chamber the dry film thickness (DFT) of plate is checked. Paint DFT: 25 TO 30 microns

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3.1.4 INSTRUMENTS USED IN PLATE PREPARATION: Steel temperature gauge: steel temperature gauge is used to check the temperature of steel plate before priming operation Hygrometer: hygrometer is used to find the dry bulb and wet bulb temperatures. Elcometer: it is used to find the dew point and relative humidity. Profile gauge: profile gauge is used to find the degree of roughness of plate surface after it has been blasted. DFT gauge: DFT gauge is used to obtain the thickness of paint deposited on plate surface after drying.

Hygrometer

Elcometer

DFT gauge

Fig.3.2 Instruments

3.1.5 COMMON TERMS USED IN PLATE PREPARATION DEPARTMENT Relative humidity: It is the term used to describe the amount of water vapour that exists in air and water vapour. DFT: It is dry film thickness of paint film deposited on the plate surface after the paint has dried.

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 Dry bulb temperature: The dry bulb temperature is the temperature of air measured by a thermometer freely exposed to air but shielded from radiation and moisture. Wet bulb temperature: It is the temperature measurement that reflects the physical properties of a system with a mixture of a gas and vapour. Dew point temperature: It is defined as the temperature to which the air would have to cool at constant and constant water vapour content in order to reach saturation.

3.2 LOFTING
Lofting is a process used for making, checking bends structure of the frames, plates by making templates. This can be done with the help of loft book or the offset table readings in offset table we have to see the waterlines marking and buttocks marking for smooth curve have shown in the figure. For checking, making bend structure marker first mark the buttocks and the waterlines the according to that mark the points on plate and to check match the points cut frames and to make the frames they make template by matching the pints and after making the templates they bend on machine. The lofting operations give a more accurate picture of the shape and dimensions first of the hull, then of almost all its component parts, subassemblies and sections separately. The main work done in the mould loft is listed in sequence which is performed when constructing a ship is as follows. Laying of the lines on full size. Lying of the body plan and the separate hull structure. Plotting and taking stretched lines and plotting hull member outlines. Constructing and preparing templates. Marking off and checking to particular specification for building berth and assembly operations.

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3.3 PLATE BENDING

To bend the plate in desired shape first we have to make the sample of that shape then after making the sample take it to the bending machine and using the horizontal arm plate bending machine bend the plate to required shape. Plunger of the machine bends the plate mainly, and plate is checked by sample that prepared for proper bending of the plate. Plate bending machine have two plunger one with round at the end and other having plate section at the end. If the plate has to bend in round shape then direct rolling machine is there which rolls the plate I round shape. Frame bending is same as like as plate bending only difference is that we have to bend the frame on frame bending machine. Which has three arms middle arm holds the frame and other two arms pull or push the frame, so to get bends, to bend the frame in the desired shape then first we have to mark approx centre of the bend shape and this centre should be exactly at the centre arm so to have proper bending of the frame, while bending we have to check that it is getting proper shape or not. All this method this bending method are trial and error method.

3.3.1. TEMPLATES
The bending of plates is carried out with help of templates. Separate templates exist for each hull plate of the vessel built. Templates change with change in design of vessel. For 2D bending of plates only transverse templates are used. For 3D bending of plates both longitudinal and transverse templates are used. Templates are made of mild steel or plywood.

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Fig.3.3 Plate bending

3.3.2 TOOLS USED FOR BENDING The tools are used for different types of bending operation such as stretching, concave bending, punching and flanging. 1 STRETCHING TOOLS The stretching tools are used for stretching plates and consists of following parts Top holder (G) Stretching die (M) Die holder (n) 2 TOOLS FOR CONCAVE BENDING The tools for concave bending are used for the bending of plates in two directions and consists of.
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 Top holder (G) Convex stamp (I) Concave die (N) 3 DEEP DRAWING TOOLS The small concave bending tools are used for bending plates in two directions with a small radius and consist of. Top holder (G) Deep drawing stamp (J) Press ring (K) Die holder (N). 4 BENDING TOOLS The bending tools are used for the bending of plates in one direction and consist of following components. Top holder (A) Four bending stamps (E) Two bending dies (F)

5 FLANGING TOOLS The following tools are used for square bending of plates and consist of. Top holder (A) Flanging die (C) Die holder (D) Five flanging stamps (B) Adjustable slopping frame

6 ROLLING TOOLS
The rolling tools are used for stretching and bending plates for stretching the flat upper and lower roll are used for bending ,the convex upper and the concave lower roll are used.

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